DIY Disc Brake Conversion
 

I've been looking at the disc brake conversion kits that cpp make. they're nice and all, but I've found a couple problems with them:
1. They don't make kits for the 1 ton trucks
2. At $375 for the 6 lug kit, it's WAY out of my price range.

It seems to me like the only thing you can't get at a junkyard is the bracket that holds the caliper. I know I can make that on the plasma cutter at school, so I'm not too worried about that.

What I'm wondering, is what holds the brake disc on the spindle?

Re: DIY Disc Brake Conversion
 

Two ways to go about it.
1, find a rotor that fits around the hub. This is what CPP does, I think, and what most modern brake systems do.
2, put the studs through the rotor and then into the hub, press to fit. This makes a single piece hub-rotor, if I recall correctly a rear wheel drive Astro is set up about the same.
If you go with option one, which will be easier, you just bolt the wheel up to the hub & the rotor gets sandwiched. It won't go anywhere - but you DO want it to be centered on the hub, so a machined spacer ring may be needed.
EDIT: Also, lots of companies make hub-centric rings to adapt lug centric wheels. You may be able to find some in the right size to center the rotor.

Re: DIY Disc Brake Conversion
 

I would take the front hub off and take it into your local parts store and see if they will pull some 8 lug rotors until you find something that will work. One guy that did it on the 1 tons used a Ford van rotor I believe. Building the bracket for the caliper should be pretty easy.

Re: DIY Disc Brake Conversion
 

all the repop stuff is for 1/2 ton trucks, but that shouldn't stop you :D
unbolt the backing plate, finding a disk that will fit you spindle will be your biggest problem
get a caliper that fits the disk application and make these

http://www.heidts.com/ProdImages/thumbs/DF-101-F.jpg

these are the adapters for a 1/2 ton truck, just adapt them to your application

http://static.speedwaymotors.com/RS/...91631981_L.jpg


read this http://static.speedwaymotors.com/pdf/910-31916.pdf

no brain surgery here, just take your time
google and look at lot of pictures

Re: DIY Disc Brake Conversion
 

just ideas

http://www.sky-manufacturing.com/new...1222901210.jpg

rear but another bracket

http://image.fourwheeler.com/f/techa...g_brackets.jpg

ford truck with king pins

http://www.ford-trucks.com/article/i...sion_img_1.jpg

your stock wheels won't fit
you'll also need to update your mc to a disk/drum application

Re: DIY Disc Brake Conversion
 

I've already got the master cylinder and brake booster, now I just need the prop valve.
Thanks Ogre, I found that page about 5 min after I started the thread.
I can't say I've ever seen a caliper with a huge spring and lever like that. Is it anything special? Or do bigger calipers just have that set up. It almost looks like it's mechanical..

You don't think the wheels will fit even if I find a chevy rotor?
If it won't fit, do they make steelies that hold the original chevrolet hubcaps?

Re: DIY Disc Brake Conversion
 

Check rotors for four wheel drives, they may be more likely to be two piece Hub and rotor. I know dodge and Chevy are the same bolt pattern. I think Ford is too but don't know for sure.
If you can't find something with the right center hole look for one with a smaller one and have a machine shop turn it to size.

Re: DIY Disc Brake Conversion
 

This is what I did on my 1 ton. I removed the drum and backing plate and bolted a 1978 Chevy 4x4 rotor to the hub. I used a caliper from a 1978 4x4 and built a bracket for the caliper.Attachment 1127357

Re: DIY Disc Brake Conversion
 

I believe that is a parking brake setup.....

Re: DIY Disc Brake Conversion
 

I used the ford rotors on the front to avoid any machine work.( used the sleeves on each stud to center the rotor - along with the bigger studs). The calipers are the 3/4 ton 4 wheel drive units,( one all 4 corners.) but mine is a 3800 pick-up not a dually. Blackbird Enterprises makes a bracket to put the calipers on the back cheaper than you can build them. I cut the bottom corner off so I could slip it over the back axle tube and bolt it on - sorry I didnt want to take the rearend apart.rear disc goes on just like you said . yep you can even use the stock studs - they will work - even long enough to engauge all the threads into the nuts.( you could put a longer set in if you just have to have 2 inchs sticking out.
I use the speed way 1/2 ton bracket as a pattern to make my front caliper brackets. I am actually using the l88 vette manual Dual MC - no booster - and a pair of 2 lb residual valves -and adjuster from speedway. It will put your nose on the dash with very little pedal pressure.(I have several photos bracket , front , and rear I can text you or email you) - I also have the entire part number list that I used at napa.
Give me a ring if you need 662 542 0796. Someone does offer a kit for the 1 ton. -You do - The reason I did mine was the very fact that everyone said it could not be done for a reasonable price.(wrecking yard could make it dirt cheap -but with gas at these prices -can't run around and look much). Also nothing like having the old 3800 look good -different -and stop safely.

LMD

Re: DIY Disc Brake Conversion
 

When I say machine work - I meant I wanted the rotor to sit on the hub without having to turn either the rotor( inside the hat ) or the hub down ( outside circumfrence) .LMD

Re: DIY Disc Brake Conversion
 

Yeap. that's what it is rear calipers have mechanical parking brakes.

Re: DIY Disc Brake Conversion
 

Nick,
For the record the backing plate bolt pattern for the 1/2,3/4, and 1 ton are all the same . Reason I used the speedway brackets as a pattern. Yea I know an expensive pattern. I thought the 1/2 ton bracket would work - and it would have but it wasn't far enough from the spindle center line to clear the rotor and mount the calipers.The 3/4 ton caliper is also a little bigger and the space between the caliper bolts is a little bigger. I also used two 3/8 thick plates over lapped to get ride of all the spacers. LMD

Re: DIY Disc Brake Conversion
 

We are cut from the same cloth! Thanks for posting without expectations of financial gain...

Re: DIY Disc Brake Conversion
 

Other Napa Parts:
# 38059 brake line for the front( right )
# 38061 brake line for the front ( left)
#82699 banjo bolt - need one for each caliper-
# TS- 728A-M - all four wheels. ( pads)

# 36846 the flexible rear brake lines ( yes even on the back they have to flex and move ) -One per side.
#36799 is the flexible line from the hard line to the rearend.
#641-3207 are the larger studs - for the front - drilled the hub and after install I spot welded each one - you could have just installed longer stock studs and used thin spacing sleeves on each stud - this centers the rotor - ( make sure that the spacers are no thicker than the rotor itself ) - still wound up using thin sleeves in the end even with the bigger studs . My reason for this was
# 1 there is no way it could not be centered - between the spacers and the tightning between the the wheel -( hole on the ford rotor is bigger )
The chevy rotor ( 3/4 ton 4 wheel drive rotor that is used on the back) - won't work on the front with out turning the hubs down - Don't leave much meat to hold the studs.
#2 Even though I have a mill/ lathe etc- This could be done without any of that- I even roughed the 3/8 plate out with a torch- then cleaned them up in the mill. Could be done with a grinder if it had to be.
Hope this helps - and if you need the photos let me know and Ill email them or text.
Oh yea dont for get the steering cross link needs to be shortened / adjusted at least 1 1/4 inches to be even close - then go to the front end shop and have the toe in /out set - I was still off almost 3/4 of an inch - And I swore I had it dead on Lol.

Re: DIY Disc Brake Conversion
 

Other Napa Parts:
# 38059 brake line for the front( right )
# 38061 brake line for the front ( left)
#82699 banjo bolt - need one for each caliper-
# TS- 728A-M - all four wheels.

# 36846 the flexible rear brake lines ( yes even on the back they have to flex and move ) -One per side.
#36799 is the flexible line from the hard line to the rearend.
#641-3207 are the larger studs - for the front - drilled the hub and after install I spot welded each one - you could have just installed longer stock studs and used thin spacing sleeves on each stud - this centers the rotor - ( make sure that the spacers are no thicker than the rotor itself ) - still wound up using thin sleeves in the end even with the bigger studs . My reason for this was
# 1 there is no way it could not be centered - between the spacers and thightening between the the wheel -( hole on the for drotor is bigger )
The chevy rotor ( 3/4 ton 4 wheel drive rotor that is used on the back) - won't work on the front with out turning the hubs down - Don't leave much meat to hold the studs.
#2 even though Have a mill/ lathe etc- This could be done without any of that- I even roughed the 3/8 plate out with a torch- then cleaned them up in the mill. Could be done with a grinder if it had to be.
hope this helps - and if you need the photos let me know and ill email them or text.
Oh yea dont for get the steering cross link needs to be shortened / adjusted at least 1 1/4 inches to be even close - then go to the front end shop and have the toe in /out set - I was still off almost 3/4 of an inch - And I swore I had it dead on Lol.

Re: DIY Disc Brake Conversion
 

Guys I have no idea why the post is here twice with several min. in between- I must of hit the enter button twice. still can't explain the time difference - Wait I was working on the time machine again - opps the government will be paying me a visit for sure now !lol

Re: DIY Disc Brake Conversion
 

The same thing happened to me just a little while ago.:lol:

Re: DIY Disc Brake Conversion
 

If you get that time machine working I need a trip back to 2005 to take care of some business...

Re: DIY Disc Brake Conversion
 

Alright.
Well thanks for the advice so far,
I'm at the point where I'm ready to make the swap.
I've just hit one minor obstacle is getting the drum off the hub.
I know people have said it's just two rivets, and you can easily hammer them apart, but I think someone replaced them with screws on mine?
I don't know. What do you guy think/suggest?

Re: DIY Disc Brake Conversion
 

Sure is nice when a guy posts high resolution photos that you can save and then expand to see what is going on.

I'd say that you are correct and someone has at one time replaced the drum and used two screws to hold the drum in place which wasn't the least bit necessary. They were riveted on the first time so they wouldn't fall off during transportation of the axle assembly.

If you have an impact screwdriver see if you can back them out. If not drill them out so you can pop the heads off and get the drum, off. It looks like you are going to want to knock the studs out and take the tin shield off the back too while you are at it.

Thinking about it the rear drums on my 71 3/4 ton GMC are held on by countersunk screws from the factory. That one is getting a disk brake conversion with brackets purchased on ebay and Chev 3/4 ton 4x4 front rotors with late 70's Cadillac Eldorado rear calipers with the park brake setup on them.

Re: DIY Disc Brake Conversion
 

Thanks for the compliment.
I like to see other people's pictures, I figured I'd make the best picture I can. For some reason, my camera just wouldn't focus for the first picture.

How'd you come to choose eldo calipers? Is there any reason for those over stock 4x4 calipers or even some 6 piston of a late model vette?

Re: DIY Disc Brake Conversion
 

single or double piston calipers will work fine unless your planning on course racing it
most 6 and 8 piston calipers are 1) expensive and 2) strictly for show

Re: DIY Disc Brake Conversion
 

Well thank you all for the responses.

Imdanderous, I went to Oreilly's, just to see which rotor would work better, and the ford rotor seems to sit awfully far back. Now while that's good for caliper clearance, I'm afraid it will make the caliper mounting bracket more difficult then I care to make it.

I too felt that turning it down was unsafe, so I opted to use one of the mills at our school. First picture is our 3D modeling software. I just made a model of the outside, because that's all I'm worried about. Then the next 2 pictures are of the renderings of how the mill will cut everything out. and last 2 is of the mill working on the first hub. We're having problems making sure the hub is perfectly lined up, but I think I have a solution for that. At least one of the hubs will guaranteed be done by next friday.

Re: DIY Disc Brake Conversion
 

When I lined up the rotor I simply took the lug nuts and tightened them up with a Impact wrench.( the tapered lug nuts centered the rotor - Magnetic dial indicator was well with in spec.) I didn't figure that there would be a need to be much more accurate than that. I also got around the deep rotor by using the overlapping caliper bracket ( look at the pics I sent you- close)that set it back far enough that I didn't have to use a bunch of spacers and junk on the brackets where it bolts to the spindle.I figured that would be the weakest place and show the greatest load.
If I had your skills and access to those kinda machines I would have done the same. Your ideas are dead on, and in the end more accurate. You also can reproduce the info so that it could be applied to any machine in the country.Making this only easier for the next guy that wants to do this. Its gonna be good -and I just like the way that the stock front and rear axles look-Carry on Brother - Carry on-

Re: DIY Disc Brake Conversion
 

Oh yea one other thing - the screws that you spoke of holding the drums on the hubs- My 3800 had them also - sure someone hasn't made a hub or axle swap?
Not that it mattered- I was reading /catching up on the article- been a while - been very busy - damn prefect gasser I am building is fun but driving me nuts also .Also managed to paint the 3800 somewhere in there between July and September - don't remember exactly what days - gotta be the enamel paint fumes-lol

Re: DIY Disc Brake Conversion
 

Well it's been a while. I've waited at school to machine the hubs, but we never had enough time to machine them right. It's hard enough to get it positioned left to right, but the fact that we need to worry about the position of rotation really killed us. I had a way of doing it, but I would need to invest in some sacrificial aluminum, which wasn't practical at all. The instructors wanted time to really think things through, but it's already been three months, and I need to get this bad boy on the road.
So I went to oreilly with the hub, and asked for the ford rotors. Nothing quite fit. The guy and I searched through their database for about 25 min and didn't find much. We thought we found a dodge rotor that fit, but we couldn't find it in the back....so we got creative. :devil:
We just started opening boxes till we found a rotor that would fit. This is what we got on our third try.
It's a rotor off a variety of chevys from 2001 to 2014
If anyone else is looking for one, it's barcode is 56999RGS
And it fits perfectly! Now I'll drill out the hub for bigger studs, and i'll be all set.

Re: DIY Disc Brake Conversion
 

Fits well too
P.s. I apologize for how ugly everything looks in the first picture, you turn the flash on, and dirt appears out of nowhere!

Re: DIY Disc Brake Conversion
 

I am in the same boat you guys are in. Only thing is I have a 3600 instead of a 3800. Does anybody know the difference in hubs? I know the lug pattern is the same, 8x6.5. Should I look at Chevy 2500 rotors instead of the 3500 rotors?

Re: DIY Disc Brake Conversion
 

I'm glad this thread has helped someone else already!
If the lug pattern is the same, get the same rotors. They'll still fit perfectly. Only thing you'll need to do is put in some bigger studs into the hub. I just went out and bought a set of 9/16 studs for mine.

Re: DIY Disc Brake Conversion
 

My hubs look like they are fastened on with screws like yours was. Did try just screw out or did you end up drilling off the heads and going from there?

Re: DIY Disc Brake Conversion
 

Ha Ha yeah, I tried unscrewing them until I stripped them and just drilled it out.
Now you don't have to worry about using those holes again anyways. If you look at the second picture in post 27, the two smaller holes are the 2 screws you have right now. The other slightly larger hole (at about 2 o clock) happens to line up with the one of the holes in the rotor. AND the rotor is threaded, so all you need to do is drill out that hole a bit, and pop in a bolt through the hub and into the rotor.
Now the only work that will need to be done to the hub is enlarge the stud holes.(and the alignment hole).
The picture is one of the new studs I bought for the truck. I went to the parts store and just asked for their generic 9/16 size stud. The problem is the different shank sizes. The new holes we need to drill will have to be countersunk.

To find out the right sizes, I sat there with a conversion chart and a caliper making sure of the right sizes. The hub will come up to the top of the spline in the picture.
To fit the spline, you'll need a 19/32 drill bit. This will allow the stud pass through the hub right up to the edge of the threads with ease. Yet it still will leave enough material for the splines to grab on.
Just below the spline, the there is that ridge. To make it fit in the hole, you'll need to use a 5/8 drill bit and counterbore it.
I haven't looked at what size I'll need for the alignment hole.

Re: DIY Disc Brake Conversion
 

Thanks for the info, I am so glad I found this thread. I was just thinking I would get the rotors, pads, calipers, studs, and lugnuts to all the same vehicle.

Re: DIY Disc Brake Conversion
 

No problem!
Yeah that's what I'm doing. Now if you can find the calipers from a junk yard, do it. They came on all all 3500's, 2500's, and i believe some 1500's from 2001 to 2014. Both trucks and vans. Reason I say this, is because the calipers were $40, but the core price was ANOTHER $40 on top of that. I found some calipers at a local yard for $15 a pop. I'd say worth saving some cash.
I just checked the wheels, it looks like you'll unfortunately need to get new wheels to fit the calipers. But your 19" rims may do the trick.

Re: DIY Disc Brake Conversion
 

Right now I'm designing the caliper bracket.
-Dark blue lines are the rotor dimensions
-Yellow lines are the caliper pistons.
I'll finish with the axle side of the mount later.
Once this is all said and done, I'll make the patterns a pdf for normal paper. Anyone that wants it can pull it off and use it for their truck.

Re: DIY Disc Brake Conversion
 

Can I do the same thing on the rear? Or is it a lot trickier? I haven't dug into the rear brakes on my truck yet.

Re: DIY Disc Brake Conversion
 

Damn your off an running with this! Thanks for sharing your hard work Nick.

Re: DIY Disc Brake Conversion
 

I believe so, but I haven't done any serious research on it. The main reason I swapped to discs was I had nothing left of my original brakes. The first picture is how I found my brakes the first time I took the drums off. The second is what the front wheel cylinders looked like. To buy all the parts to put this back together cost me about the same as putting discs on. The rear
was intact, and I figured any load I put in the back that would require disc brakes to stop it, would ruin my wood bed floor first. So I'm keeping the drums in the rear for now.

Thank you for your kind words! I figured someone else like me in a year or two will find this thread and whip up some newer better brakes in a month or two.

Today I went to the yard and picked up some used calipers off 07 3500 van. The core charge for these were $40, and I payed $20 for these used ones. Always good saving some cash.

Now I also bought two wheels off the van. Now while these rotors are fairly tall, it looks like the caliper may hit the wheel. I'm not entirely sure. But just to be safe, plus it doesn't really hurt considering it was $10 a wheel.

Re: DIY Disc Brake Conversion
 

good work mechanixman. good luck on your caliper bracket

Re: DIY Disc Brake Conversion
 

The back caliper brackets can be ordered from blackbird enterprises. They specialize in rock crawlers. These people like the HO 52/72 rear ends. I bought them as in a pair for 99$ and cut the far corner off and slid it over the axle tube after I ground a chamfer to clear the factory housing welds. I used the 85 3/4 ton rotor and mounted them to the back if the rear hubs using the studs when pressed back in. I listed the needed parts list earlier in this thread. For the record the late 14 bolt rear has the same bolt spacing for the caliper brackets. The blackbird site says they are one in the same. I just ditched the aluminum spacers that they sent. The rear end was very straight far ward compared to the front. Hope this helps.
LMD